Method and apparatus for operating a bale opening machine

Abstract

A method and an apparatus for operating a bale opening machine having an opening member, wherein the height profile of a row of bales is determined by at least one sensor directed towards the bale surface and is used to control the position of the opening member during the subsequent bale opening. The received signal of the sensor, which is preferably an optical or acoustical sensor or a sensor which operates with radar waves, is processed to obtain a signal corresponding to the hardness of the bales. In addition, the in-feed and, optionally, the penetration of the opening member, is controlled or regulated in accordance with the hardness signal. Various slip-free length measuring devices serves to determine the longitudinal position of the opening member along the row of bales.

What is claimed is: 
     
       1. A method of operating a bale opening machine having an opening member comprising the steps of: determining a height profile of a row of bales by directing at least one sensor towards respective bale surfaces of bales in said row of bales;   obtaining a sensor signal from said at least one sensor for subsequent control of the position of the opening member during a subsequent bale opening procedure;   processing said sensor signal to produce at least a bale hardness signal; and   controlling in-feed of said opening member with respect to said bales as a function of said hardness signal.   
     
     
       2. The method of claim 1, said at least one sensor including an optical sensor, said step of directing at least one sensor towards respective bale surfaces comprising directing said optical sensor towards said respective bales surfaces. 
     
     
       3. The method of claim 1, said at least one sensor including an acoustical sensor, said step of directing at least one sensor towards respective bale surfaces comprising directing said acoustical sensor towards said respective bales surfaces. 
     
     
       4. The method of claim 1, said at least one sensor including a radar wave sensor, said step of directing at least one sensor towards respective bale surfaces comprising directing said radar wave sensor towards said respective bales surfaces. 
     
     
       5. The method of claim 1, said step of controlling in-feed of said opening member with respect to said bales as a function of said hardness signal comprising regulating said in-feed of said opening member with respect to said bales as a function of said hardness signal. 
     
     
       6. The method of claim 1, further comprising the step of controlling penetration of said opening member with respect to said bales as a function of said hardness signal. 
     
     
       7. The method of claim 1, said step of processing said sensor signal to obtain at least a bale hardness signal further comprising processing said sensor signal to obtain a hardness profile for said row of bales, said method further comprising the step of determining an in-feed profile for said row of bales as a function of said height profile and said hardness profile for maintaining optimized production of said bale opening machine during opening of bales having different origins. 
     
     
       8. The method of claim 7, further comprising making multiple passes of said bale opening machine along said row of bales and, during said multiple passes, opening said bales as a function of said height profile and said hardness profile to minimize bale remainders. 
     
     
       9. The method of claim 8, said step of opening said bales as a function of said height profile and said hardness profile to minimize bale remainders being controlled by a computer, and further comprising programming said computer for controlling said step of opening said bales to progressively achieve a horizontal line. 
     
     
       10. The method of claim 7, said step of directing said at least one sensor towards respective bale surfaces for determining said height profile being performed during a first pass of said bale opening machine along said row of bales, said method further comprising the step of opening said row of bales during said first pass of said bale opening machine. 
     
     
       11. The method of claim 10, said step of opening said row of bales during said first pass of said bale opening machine comprising moving said opening member at a generally constant height during said first pass. 
     
     
       12. The method of claim 10, said step of opening said row of bales during said first pass of said bale opening machine comprising moving said opening member in a predetermined stepwise manner as a function of said height profile. 
     
     
       13. The method of claim 12, further comprising performing additional passes of said bale opening machine, said opening member being manipulated during said additional passes to obtain an approximately maximum opening amount during each additional pass and to obtain a minimum height profile during a final pass of said bale opening machine. 
     
     
       14. The method of claim 1, further comprising the step processing said sensor signal for determining an end of said row of bales. 
     
     
       15. The method of claim 1, further comprising the step processing said sensor signal for determining a beginning and an ending of said row of bales. 
     
     
       16. The method of claim 1, further comprising the step of processing said sensor signal for determining presence and length of gaps between bales in said row of bales. 
     
     
       17. The method of claim 1, further comprising: setting a maximum opening depth of said opening member;   making at least a first, second, third, and fourth consecutive pass along said row of bales with said opening member, wherein:   during said first pass, said opening member is guided to follow upper bale surfaces of said bales step-wise during said step of determining a height profile;   said step of controlling in-feed of said opening member with respect to said bales as a function of said hardness signal comprises guiding said opening member at a constant height during said second pass and during said third pass to not exceed said maximum opening depth; and   during no later than said fourth pass, said upper surfaces of said bales are substantially levelled with respect to each other.   
     
     
       18. A method of operating a bale opening machine having an opening member comprising the steps of: determining a height profile of a row of bales by directing at least one sensor towards respective bale surfaces of bales in said row of bales,   obtaining a sensor signal from said at least one sensor for subsequent control of the position of the opening member during a subsequent bale opening procedure;   processing said sensor signal to produce at least a bale hardness signal;   said step of processing said obtained sensor signal to produce a bale hardness signal comprising the step of sensing and processing amplitude fluctuations of said sensor signal; and   controlling in-feed of said opening member with respect to said bales as a function of said hardness signal.   
     
     
       19. The method of claim 18, said step of sensing and processing amplitude fluctuations of said sensor signal comprising summing deviations of said sensor signal which have a positive sign from the mean value of said sensor signal. 
     
     
       20. The method of claim 18, said sensor signal having a basic frequency, and said step of sensing and processing amplitude fluctuations of said sensor signal comprising scanning said sensor signal at a frequency which is at least twice said basic frequency of said sensor signal. 
     
     
       21. The method of claim 18, further comprising the steps of periodically starting said sensor; directly transferring instantaneous measured values of said sensor signal to a computer in digital form; and storing said instantaneous measured values in said computer in an array. 
     
     
       22. The method of claim 18, said step of processing said obtained sensor signal to produce a bale hardness signal comprising deriving a separate hardness signal of each bale in said row of bales. 
     
     
       23. A method of operating a bale opening machine having an opening member comprising the steps of: determining a height profile of a row of bales by directing at least one sensor towards respective bale surfaces of bales in said row of bales;   obtaining a sensor signal from said at least one sensor for subsequent control of the position of the opening member during a subsequent bale opening procedure;   processing said sensor signal to produce at least a bale hardness signal;   controlling in-feed of said opening member with respect to said bales as a function of said hardness signal;   a first row of bales being positioned on one side of said bale opening member and a second row of bales being positioned on another side of said bale opening member; and   said step of determining a height profile of a row of bales comprising determining a height profile of said first row of bales while opening said second row of bales.   
     
     
       24. A method of operating a bale opening machine having an opening member comprising the steps of: determining a height profile of a row of bales by directing at least one sensor towards respective bale surfaces of bales in said row of bales;   obtaining a sensor signal from said at least one sensor for subsequent control of the position of the opening member during a subsequent bale opening procedure;   processing said sensor signal to produce at least a bale hardness signal;   controlling in-feed of said opening member with respect to said bales as a function of said hardness signal;   said step of obtaining a sensor signal further comprising obtaining a signal which is proportional to a path of travel of said opening member; and   said method further comprising the step of obtaining a hardness profile as a function of said path of travel signal.   
     
     
       25. A method of operating a bale opening machine having an opening member comprising the steps of: determining a height profile of a row of bales by directing at least one sensor towards respective bale surfaces of bales in said row of bales;   obtaining a sensor signal from said at least one sensor for subsequent control of the position of the opening member during a subsequent bale opening procedure;   processing said sensor signal to produce at least a bale hardness signal;   controlling in-feed of said opening member with respect to said bales as a function of said hardness signal;   said step of obtaining a sensor signal further comprising obtaining a signal which is proportional to a path of travel of said opening member; and   said method further comprising the steps of obtaining an in-feed depth profile as a function of said path of travel signal.   
     
     
       26. A method of operating a bale opening machine having an opening member comprising the steps of: determining a height profile of a row of bales by directing at least one sensor towards respective bale surfaces of bales in said row of bales;   obtaining a sensor signal from said at least one sensor for subsequent control of the position of the opening member during a subsequent bale opening procedure;   processing said sensor signal to produce at least a bale hardness signal;   controlling in-feed of said opening member with respect to said bales as a function of said hardness signal;   said step of obtaining a sensor signal further comprising obtaining a signal which is proportional to a path of travel of said opening member; and   said step of determining said height profile comprising determining said height profile as a function of said path of travel signal.   
     
     
       27. A method of operating a bale opening machine having an opening member comprising the steps of: determining a height profile of a row of bales by directing at least one sensor towards respective bale surfaces of bales in said row of bales;   obtaining a sensor signal from said at least one sensor for subsequent control of the position of the opening member during a subsequent bale opening procedure;   processing said sensor signal to produce at least a bale hardness signal;   controlling in-feed of said opening member with respect to said bales as a function of said hardness signal;   said step of obtaining a sensor signal further comprising obtaining a signal which is proportional to a path of travel of said opening member; and   said method further comprising the steps of obtaining a hardness profile and an in-feed depth profile as a function of said path of travel signal.   
     
     
       28. A method of operating a bale opening machine having an opening member comprising the steps of: determining a height profile of a row of bales by directing at least one sensor towards respective bale surfaces of bales in said row of bales;   obtaining a sensor signal from said at least one sensor for subsequent control of the position of the opening member during a subsequent bale opening procedure;   processing said sensor signal to produce at least a bale hardness signal;   controlling in-feed of said opening member with respect to said bales as a function of said hardness signal;   said step of directing said at least one sensor towards respective bale surfaces of determining said height profile being performed during a first pass of said bale opening machine along said row of bales; and   said method further comprising the step of opening said row of bales during said first pass of said bale opening machine.   
     
     
       29. The method of claim 28, said step of opening said row of bales during said first pass of said bale opening machine comprising moving said opening member at a generally constant height during said first pass. 
     
     
       30. The method of claim 28, said step of opening said row of bales during said first pass of said bale opening machine comprising moving said opening member in a predetermined stepwise manner as a function of said height profile. 
     
     
       31. A method of operating a bale opening machine having an opening member comprising the steps of: determining a height profile of a row of bales by directing at least one sensor towards respective bale surfaces of bales in said row of bales;   obtaining a sensor signal from said at least one sensor for subsequent control of the position of the opening member during a subsequent bale opening procedure;   processing said sensor signal to produce at least a bale hardness signal;   controlling in-feed of said opening member with respect to said bales as a function of said hardness signal;   said step of processing said sensor signal to obtain at least a bale hardness signal further comprising processing said sensor signal to obtain a hardness profile for said row of bales;   said method further comprising the step of determining an in-feed profile for said row of bales as a function of said height profile and said hardness profile for maintaining optimized production of said bale opening machine during opening of bales having different origins; and   further comprising the step of determining a preset desired fiber flock opening value for said opening machine, an actual opening value being determined as a function of in-feed depth of said opening member and said hardness signal, and regulating said in-feed depth of said opening member to achieve said preset desired fiber flock opening value or approximately said preset desired fiber flock opening value.   
     
     
       32. A method of operating a bale opening machine having an opening member comprising the steps of: determining a height profile of a row of bales including the step of directing at least one distance measuring sensor towards surfaces of the bales during the passing of said opening member along said row of bales;   determining the respective hardness of the bales of said row of bales as a function of signals obtained by said at least one distance measuring sensor and obtaining a hardness profile for said row of bales; and   controlling the position of the opening member during subsequent bale opening as a function of said height profile and said hardness profile.   
     
     
       33. The method of claim 32, said step of directing at least one distance measuring sensor towards surfaces of the bales comprising directing said sensor in a predetermined direction to obtain a signal representative of the distance to respective upper surfaces of said bales between a starting point of said row and an ending point of said row. 
     
     
       34. The method of claim 33, said step of directing at least one distance measuring sensor towards surfaces of the bales further comprising determining whether gaps are present between said bales in said row of bales by directing said distance measuring sensor toward a floor surface, supporting said bales, during the passing of said opening member along said row of bales. 
     
     
       35. The method of claim 32, the step of directing at least one distance measuring sensor towards surfaces of the bales during the passing of said opening member along said row of bales comprising the step of directing an optical sensor towards surfaces of the bales during the passing of said opening member along said row of bales. 
     
     
       36. The method of claim 32, the step of directing at least one distance measuring sensor towards surfaces of the bales during the passing of said opening member along said row of bales comprising the step of directing an acoustical sensor towards surfaces of the bales during the passing of said opening member along said row of bales. 
     
     
       37. The method of claim 32, the step of directing at least one distance measuring sensor towards surfaces of the bales during the passing of said opening member along said row of bales comprising the step of directing a radar wave sensor towards surfaces of the bales during the passing of said opening member along said row of bales. 
     
     
       38. The method of claim 32, further comprising: setting a maximum opening depth of said opening member;   making at least a first, second, third, and fourth consecutive pass along said row of bales with said opening member, wherein:   during said first pass, said opening member is guided to follow upper bale surfaces of said bales step-wise during said step of determining a height profile;   said step of controlling the position of the opening member during subsequent bale opening as a function of said height profile comprises guiding said opening member at a constant height during said second pass and during said third pass to not exceed said maximum opening depth; and   during no later than said fourth pass, said upper surfaces of said bales are substantially levelled with respect to each other.   
     
     
       39. An apparatus for operating a bale opening machine comprising: an opening member for opening at least one row of bales, said opening member being vertically movable to define a height of said opening member with respect to a support surface;   means for determining a height profile of said row of bales comprising at least one distance measuring sensor;   means for controlling said height of said opening member, as said opening member moves along said row of bales, in response to the height profile determined by said determining means; and   means for determining the respective hardness of the bales of said row of bales as a function of signals obtained by said at least one distance measuring sensor.   
     
     
       40. The apparatus of claim 39, said distance measuring sensor being an optical sensor. 
     
     
       41. The apparatus of claim 39, said distance measuring sensor being an acoustical sensor. 
     
     
       42. The apparatus of claim 39, said distance measuring sensor being a radar wave sensor. 
     
     
       43. The apparatus of claim 39, said distance measuring sensor comprising means for obtaining a signal representative of a distance from said distance measuring sensor and respective upper bale surfaces. 
     
     
       44. The apparatus of claim 39, said distance measuring sensor comprising means for obtaining a signal representative of a distance from said distance measuring sensor and said support surface. 
     
     
       45. The apparatus of claim 39, said means for determining a height profile comprising means for determining presence and length of gaps between bales. 
     
     
       46. The apparatus of claim 39, said means for determining a height profile comprising means for determining an end of said row of bales. 
     
     
       47. The apparatus of claim 46, said means for determining a height profile comprising means for determining a beginning and an ending of said row of bales. 
     
     
       48. The apparatus of claim 39, further comprising means for controlling an in-feed of said opening member as a function of the respective hardness of the bales as determined by said means for determining the respective hardness of the bales. 
     
     
       49. The apparatus of claim 48, further comprising means for controlling penetration depth of the of said opening member as a function of the respective hardness of the bales as determined by said means for determining the respective hardness of the bales. 
     
     
       50. The bale opening apparatus of claim 39, further comprising a distance measuring sensor for determining a longitudinal position of said opening member. 
     
     
       51. The bale opening apparatus of claim 50, further comprising means for controlling movement of said opening member in response to signals received from said distance measuring sensor for determining a longitudinal position of said opening member. 
     
     
       52. The bale opening apparatus of claim 51, said means for controlling movement of said opening member comprising a computer. 
     
     
       53. A bale opening apparatus comprising: an opening member for opening at least one row of bales;   means for supporting said opening member in a longitudinal direction along said row of bales for opening said bales;   means for supporting said opening member for vertical movement for establishing a height of said opening member with respect to a support surface;   means for determining a height profile of said row of bales comprising at least one distance measuring sensor;   means for controlling said height of said opening member, as said opening member moves along said row of bales, in response to the height profile determined by said determining means;   said means for supporting said opening member for vertical movement comprising an arm to which said opening member is supported;   said arm having a front portion, with respect to said longitudinal direction for opening said bales;   said distance measuring sensor being positioned on said front portion of said arm;   said at least one distance measuring sensor comprising a plurality of distance measuring sensors, for parallel operation, mounted on said front portion of said arm;   said arm further having a rear portion; and   said at least one distance measuring sensor further comprising a further distance measuring sensor positioned on said rear portion of said arm.   
     
     
       54. A bale opening apparatus comprising: an opening member for opening at least one row of bales;   means for supporting said opening member in a longitudinal direction along said row of bales for opening said bales;   means for supporting said opening member for vertical movement for establishing a height of said opening member with respect to a support surface;   means for determining a height profile of said row of bales comprising at least one distance measuring sensor;   means for controlling said height of said opening member, as said opening member moves along said row of bales, in response to the height profile determined by said determining means; and   means for determining the respective hardness of the bales of said row of bales as a function of signals obtained by said at least one distance measuring sensor.   
     
     
       55. The bale opening apparatus of claim 54, said means for supporting said opening member for vertical movement comprising an arm to which said opening member is supported, said arm having a front portion, with respect to said longitudinal direction for opening said bales, said distance measuring sensor being positioned on said front portion of said arm. 
     
     
       56. The bale opening apparatus of claim 55, said at least one distance measuring sensor comprising a plurality of distance measuring sensors, for parallel operation, mounted on said front portion of said arm. 
     
     
       57. A bale opening apparatus comprising: an opening member for opening at least one row of bales;   means for supporting said opening member in a longitudinal direction along said row of bales for opening said bales;   means for supporting said opening member for vertical movement for establishing a height of said opening member with respect to a support surface;   means for determining a height profile of said row of bales comprising at least one distance measuring sensor;   means for controlling said height of said opening member, as said opening member moves along said row of bales, in response to the height profile determined by said determining means;   (a) a non-slipfree drive system;   (b) a travelling tower which is movable by means of said drive system along the bale row and supporting said opening member; and   (c) a distance of travel measuring device comprising: (1) an elongated part adapted to extend along the bale row;   (2) means for sensing said elongated part in a slipfree manner during movement of said opening member along the bale row;   (3) means for transmitting a pulse signal at the occurrence of a predetermined increment of movement of said tower along said bale row; and   (4) means for counting said pulse signals and generating a signal representative of distance travelled by said tower along said bale row.     
     
     
       58. The bale opening apparatus of claim 57, further comprising a fiber flock transport channel, said elongated part being secured to said channel. 
     
     
       59. A bale opening apparatus comprising: an opening member for opening at least one row of bales;   means for supporting said opening member in a longitudinal direction along said row of bales for opening said bales;   means for supporting said opening member for vertical movement for establishing a height of said opening member with respect to a support surface;   means for determining a height profile of said row of bales comprising at least one distance measuring sensor;   means for controlling said height of said opening member, as said opening member moves along said row of bales, in response to the height profile determined by said determining means; and   a distance measuring sensor for determining a longitudinal position of said opening member.   
     
     
       60. A bale opening apparatus of claim 59, further comprising means for controlling movement of said opening member in response to signals received from said distance measuring sensor for determining a longitudinal position of said opening member. 
     
     
       61. The bale opening apparatus of claim 60, said means for controlling movement of said opening member comprising a computer. 
     
     
       62. A bale opening apparatus comprising: an opening member for opening at least one row of bales;   means for supporting said opening member in a longitudinal direction along said row of bales for opening said bales;   means for supporting said opening member for vertical movement for establishing a height of said opening member with respect to a support surface;   means for determining a height profile of said row of bales comprising at least one distance measuring sensor;   means for controlling said height of said opening member, as said opening member moves along said row of bales, in response to the height profile determined by said determining means;   said means for supporting said opening member in a longitudinal direction along said row of bales for opening said bales further comprising a longitudinally movable and rotatable tower adapted to open rows of bales positioned on either longitudinal side of said tower; and   said opening member being mounted on one side of said tower and said distance measuring sensor being located on said tower laterally opposite said opening member.